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Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-1 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-1 SECTION 303-03A Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma VEHICLE APPLICATION: 2011.50 Ranger CONTENTS PAGE SPECIFICATIONS Specifications 303-03A-2 DESCRIPTION AND OPERATION Engine Cooling 303-03A-3 Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine 303-03A-3 GENERAL PROCEDURES Cooling System Draining, Filling and Bleeding — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (24 122 0) Draining Filling Bleeding 303-03A-5 303-03A-5 303-03A-5 303-03A-5 REMOVAL AND INSTALLATION Thermostat (24 454 0) Thermostat Housing (24 001 0) Coolant Pump (24 404 0) Radiator (24 254 0) Cooling Fan Motor and Shroud (24 222 0) Coolant Outlet Connector 303-03A-7 303-03A-8 303-03A-9 303-03A-11 303-03A-13 303-03A-15 Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-2 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-2 SPECIFICATIONS Antifreeze Specifications Description Specification Motorcraft Super Plus 2000 WSS-M97B44-D Specific gravity (providing no other additive is in the coolant) 1.068 at +15°C Approximate percentage of antifreeze (by volume) 50% Coolant remains fluid to -30°C (-22°F) Coolant solidifies at -35°C (-31°F) Cooling System Capacities — Vehicles with 2.2L Diesel Engine Description Vehicles with front heater only Cooling System Pressure Specification Description Liters 11.5 Pressure kPa (psi) Radiator pressure test 138 (20) Coolant expansion tank cap release pressure 135-155 (19-22) 2011.50 Ranger G1272392en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-3 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-3 DESCRIPTION AND OPERATION Engine Cooling Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine Item Description Radiator Coolant expansion tank Thermostat housing Coolant pump Cooling fan motor and shroud 2011.50 Ranger CAUTION: If the coolant concentration is insufficient, low temperature protection and corrosion resistance will be inadequate NOTE: Providing the coolant has not been contaminated with other fluids or foreign material, the robust corrosion resistance properties of this coolant means that it can be reused after changing an aluminium cooling system component The G1272393en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-4 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-4 DESCRIPTION AND OPERATION concentration should always be checked and maintained within specification Coolant concentration should be checked through the neck of the coolant expansion tank with a hydrometer The acceptable range of specific gravity (sg) must be maintained The coolant used is an orange colored Motorcraft Super Plus 2000 engine coolant This is a non silicated organic acid technology (OAT) coolant that must not be mixed with other coolant types For cooling system top up, only use coolant which meets the correct specification 2011.50 Ranger G1272393en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-5 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-5 GENERAL PROCEDURES Cooling System Draining, Filling and Bleeding — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma(24 122 0) Draining WARNING: When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Release the cooling system pressure by slowly turning the coolant expansion tank cap between and turns Remove the radiator drain plug and drain the coolant Install the radiator drain plug Lower the vehicle Filling Refill the coolant to the expansion tank to maximum line (+15mm) Bleeding CAUTION: The fluid level must remain between the MAX and MIN marks Run the engine for minutes at idle rpm 2011.50 Ranger G1345983en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-6 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-6 GENERAL PROCEDURES Install the coolant expansion tank cap Run the engine speed to 2500 RPM and maintain it for approximately 15 minutes Run the engine for 5minutes at idle rpm Switch the engine off Check the cooling system for leaks Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Torque: 30 Nm Lower the vehicle 10 Allow the engine to cool and maintain close to room temperature 11 Fill the coolant to the expansion tank max fill line, if required 2011.50 Ranger G1345983en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-7 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-7 REMOVAL AND INSTALLATION Thermostat(24 454 0) Removal NOTE: Removal steps in this procedure may contain installation details Drain the cooling system Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) Bleed the cooling system Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) Torque: 10 Nm Installation NOTE: Inspect the thermostat housing cover O-ring seal Install a new O-ring seal if necessary To install, reverse the removal procedure 2011.50 Ranger G1272394en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-8 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-8 REMOVAL AND INSTALLATION Thermostat Housing(24 001 0) Torque: 23 Nm Removal NOTE: Removal steps in this procedure may contain installation details Drain the cooling system Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) Installation To install, reverse the removal procedure Bleed the cooling system 2011.50 Ranger Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) G1272395en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-9 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-9 REMOVAL AND INSTALLATION Coolant Pump(24 404 0) Removal NOTE: Removal steps in this procedure may contain installation details Drain the cooling system Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Refer to: Accessory Drive Belt - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-05 Accessory Drive - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation) Torque: 14 Nm 2011.50 Ranger Torque: 23 Nm Torque: 23 Nm G1272396en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-10 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-10 REMOVAL AND INSTALLATION NOTE: Use care when cleaning the water pump gasket mating surfaces Gouges in the aluminum could form leak paths Installation To install, reverse the removal procedure Bleed the cooling system Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) 2011.50 Ranger G1272396en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-11 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-11 REMOVAL AND INSTALLATION Radiator(24 254 0) Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Cooling Fan Motor and Shroud (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation) 2011.50 Ranger NOTE: Take extra care not to damage the A/C refrigerant filling pipe G1272397en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-12 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-12 REMOVAL AND INSTALLATION Torque: 20 Nm NOTE: Take extra care not to damage the radiator during removal Lift the A/C condenser off the supports and move the A/C condenser toward the front of the vehicle and securely strap the A/C condenser on the grill support Torque: Nm Installation NOTE: Make sure that no components catch when installing the radiator To install, reverse the removal procedure NOTE: Radiator insulators are to be reused unless damaged 2011.50 Ranger G1272397en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-13 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-13 REMOVAL AND INSTALLATION Cooling Fan Motor and Shroud(24 222 0) Special Tool(s) 303-1196 Holding Wrench, Pulley 303-378 Wrench, Fan Hub Removal NOTE: Removal steps in this procedure may contain installation details Drain the cooling system Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) 2011.50 Ranger G1272398en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-14 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-14 REMOVAL AND INSTALLATION Torque: 105 Nm Special Tool(s): 303-378, 303-1196 Remove the fan and position it inside the shroud Lift the fan and shroud together and remove from the vehicle Installation To install, reverse the removal procedure Bleed the cooling system Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) 2011.50 Ranger G1272398en Engine Cooling — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-15 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A-15 REMOVAL AND INSTALLATION Coolant Outlet Connector Removal NOTE: Removal steps in this procedure may contain installation details Drain the cooling system Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Installation To install, reverse the removal procedure Bleed the cooling system Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Refer to: Accessory Drive Belt - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-05 Accessory Drive - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation) NOTE: Make sure that these components are installed to the noted removal position NOTE: The gasket is to be reused unless damaged Torque: 23 Nm Torque: 48 Nm 2011.50 Ranger G1355951en